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MZG / GRAB ACCESSORIES

MOTOR GRAB GRAB ACCESSORIES

&
GENERAL ARRANGEMENT GRAB

SUSPENSION

CYLINDER
UPPER
TRAVERSE

STEERING
ARM

LOWER
TRAVERSE
WITH OIL
TANK

SCOOPS

KICK PLATES
UPPER
STEERING CAP NUT
ARM PIN

ELECTRICAL
CONNECTION
PISTON ROD

BRACKETS
FOR TENSION HYDRAULIC
RELEASE UNIT
(INSIDE)

SCOOP PIVOT
POINT

LOWER
STEERING
ARM PIN
HYDRAULIC ARRANGEMENT
B LINE
ELECTRIC (OPENING)
MOTOR

A LINE
(CLOSING)
TANK
LINE

CONTROL HYDRAULIC
BLOCK PUMP
HYDRAULIC UNIT

E - MOTOR
(TYPE: 200-L)
CONTROL BLOCK LEAK OIL
PUMP
(TYPE: NG30 E) BEARING

HYDRAULIK PUMP
(TYPE: V30D-095-BKN-LLS) LEAK OIL
PUMP
HOUSING
LS LINE
(LOAD SENSING CONTROL /
POWER DEMAND & VOLUME
SUPPLY )

RV3 / CHECK
VALVE WITH RV4 / CHECK
PRESSURE VALVE WITH
RELEASE PRESSURE
(SUCTION VALVE)
RELEASE
(SUCTION VALVE)
P2 LINE P1 LINE
(OPENING) (CLOSING)
CONTROL BLOCK

Lift Control
SV1

T-LINE
A-Line
(TANK) closing

B-Line
(opening)
Lift Control
SV2

PRESSURE RELEASE VALVE


DV2
PRESSURE RELEASE VALVE
DV1
HYDRAULIC PUMP

LS REGULATOR
(FOR POWER DEMAND
& VOLUME SUPPLY )

L REGULATOR
(FOR POWER DEMAND)

MAX VOLUME
CONTROL
(FULL STROKE)

STROCKE IS CONTROLLED
BY THE LS REGULATOR

MIN VOLUME
CONTROL RV4 / CHECK VALVE WITH
(ZERO STROKE) PRESSURE RELEASE
(SUCTION VALVE)
LIFTING CYLINDER

CAP NUT

PISTON ROD

GUIDE BUSH

TUBE

BUSH
LIFTING CYLINDER

Cap Nut locking A-Line


closing

Messuring
Piont

Piston

B-Line Grease Nippel


opening
GUIDE BUSH

KANTSEAL RIMSEAL
SCRAPER (light)

STEPSEAL
ROD GUIDE RING ROD GUIDE RING (dark)
PISTON

PISTON GUIDE RING


O-RING

PISTON GUIDE RING GLYD RING


FILTER & DIPSTICK

FILTER
Assembled in the Reversing line

Filtration rate 10 μ
(minimum particle size 0,01mm)

OIL DIPSTICK and SEALING


Oil level check in closed
grab position.
Oil level between
Minimum and Maximum
HYDRAULIC – OIL - TANK

OIL ISO-viscosity VG 46
HLP 46 corrosp. DIN51524/2

OIL TABLE ATACHED!

Brand of used oil:


FUCHS RENOLIN B15 VG 46
Fuchs Ident No: A2480190
HYDRAULIC DIAGRAM
Operation mode: Reversing operation (S3)
Variable delivery pump (Power regulator plus Load-Sensing regulator)
Control block NG 30-E-LS
GENERAL

Operation mode S3, also called reversing operation, means that the electric motor and thus also the pump are
operated in clockwise rotary sense as well as anticlockwise rotary sense, thus influencing the opening and closing
motion of the grab.
This grab is equipped with a power-regulated axial piston pump with additional load-sensing regulator (LS).
The power regulator of the pump is adjusted to the maximum drive motor power output, i.e. depending on the drive
power, the output of the pump is continuously adjusted to the power output of the drive motor as the operating
pressure continues to increase after having exceeded a certain level. Thus, the hydraulic power, the product of pump
output and pressure, remains constant.
The load-sensing regulator, for short LS regulator, only serves as „min./max.-regulator“. Via the LS regulator the
pump recognizes that:
1. A consumer has been connected and the pump must switch to max. output,
2. A system pressure preset at the pressure relief valve (DV1 or DV2) has been reached and the pump
has to change down towards "zero-lift regulation", so that only as much hydraulic fluid is displaced as is necessary
for compensating the gap leakage in pump and system.
Legend:
A = line (grab closing)
B = line (grab opening)
D1, D2 = nozzle
DV1, DV2 = pressure relief valve
F = filter
KS = piston side
KSS = piston rod side
LS = Load-Sensing line (LS-line)
M = electric motor
MA = pressure gauge connection, cylinder pressure (closing)
MB = pressure gauge connection, cylinder pressure
(opening)
MLS = pressure gauge connection for LS-signal pressure
MP1 = pressure gauge connection, closing pressure
MP2 = pressure gauge connection, opening pressure
P = hydraulic pump
P1, P2 = pressure line pump / control block
R1, R2 = nonreturn valve
RV3, RV4 = nonreturn valve (check valve) with pressure relief valve
St1, St2 = control line
SV1, SV2 = stop valve with lift stop
T = tank connection
WV = shuttle valve
General: Pressure line

Signal line

None return valve

None return valve /


pressure controlled

Lift Stop (Adjustable)

None return valve /


pressure controlled
with lift stop
Pressure release valve

Pressure release valve /


adjustable

Ø1
Nozzle

connection
Closing procedure:
As soon as the drive motor M is started, the hydraulic pump P sucks hydraulic oil via
nonreturn valve RV4 out of the tank and pumps it into pressure line P1.

The oil flows via nonreturn valve R1 and line A into the piston rod sides KSS of
the lifting cylinders. At the same time, the pilot controlled stop valve SV2 is
opened via control line St2. The oil returning from the piston sides KS can now
return to the tank via SV2, tank line T and filter F.

The maximum pressure in pipe A is controlled by the pressure relief valve DV1.
As soon as the maximum pressure (preset at DV1) is reached, the output of pump
P is reduced (see paragraph "Power regulation").
When the drive motor is switched off, the nonreturn valves R1, R2 and the pilot
controlled stop valves SV1, SV2 avoid automatic opening or closing of the grab.
CLOSING

SV1
SV2 CLOSED
OPEN

R1
OPEN
R2
CLOSED

LS Signal
(Pump at
Maximum Lift)

RV3
CLOSED
Grab Closed

SV1
SV2 Closed
OPEN

R1
OPEN
R2
CLOSED

DV1
Open
(230bar)

LS Signal
(Pump at zero lift)
GRAB CLOSED
&
MOTOR STOPPED PRESSURE
STAYS IN THE
CYLINDER!
SV2 SV1
CLOSED CLOSED
CONDITION

R1
CLOSED
CONDITION

R2
CLOSED
Opening procedure:

As soon as the drive motor M is started, the hydraulic pump P sucks hydraulic oil
via nonreturn valve RV3 out of the tank and pumps it into pressure line P2.

The oil flows via the nonreturn valve R2 and pipe B into the piston sides KS of the
lifting cylinders. On extension of the cylinders, the oil flowing off the piston rod
sides KSS via pipe A then flows via the stop valve SV1 opened by the control line
St1 to pipe B and additionally fills piston side KS (quick-motion mode). During the
opening procedure no oil returns to the tank.

The maximum pressure in pipe B is controlled by the pressure relief valve DV2. As
soon as the maximum pressure (preset at DV2) is reached, the output of the pump
P is reduced (see under „General“).
OPENING
QUICK RUN
ACTION
SV1
SV2 OPENED
CLOSED

R1
CLOSED
R2
OPEN

LS Signal
(Pump at
Maximum Lift)

RV4
CLOSED
Grab OPEN

SV2
CLOSED
CONDITION SV1
OPENED
CONDITION
R2
OPEN
R1
CLOSED

DV2
Open
(120bar)

LS Signal
(Pump at zero lift)
GRAB OPEN
& PRESSURE
MOTOR STAYS IN THE
STOPPED CYLINDER!
SV1
CLOSED
CONDITION

SV2
CLOSED
R1
CLOSED
CONDITION
R2
CLOSED
Rattling of the shells:
In order to avoid a rattling of the shells during the closing procedure, the
pilot-controlled nonreturn valve SV should be slightly throttled (setting by
means of adjusting screws,).

ATTENTION ! SV must not be closed too much to avoid extreme


heating of the oil.
ATTENTION ! During load-lifting it must be observed that the grab is closed until the lifted load is suspended safely in the scoops when lifting
the grab.
Pressure to be set at DV1 and DV2.
(see data sheet for pressure values)

DV1 = closing
DV2 = opening

Security valves RV3; RV4:


The complete hydraulic system is protected by the security valves (RV3; RV4). The security valves must always be set approx. 30 - 50 bar higher than the
system pressure valves (DV1, DV2). Normally they are set at 280 bar ex works and should never be adjusted.

Pressure gauge connections:


The system pressures can be checked at the provided measuring points (pressure values see data sheet).

Closing: on cylinder, on ring line, MP1, MA


Opening: on cylinder, on ring line, MP2, MB

Pump pressure: MP
LS-pressure: MLS
GENERAL ARRANGEMENT GRAB ACCESSORIES

CABLE
FOR GRAB
POWER SUPPLY

ROPE
ELECTRICAL STABILISATION
INSTALLATION DRUM
(INSIDE)

DEFLECTION GUIDE CABLE


SHEAVE SHEAVES DRUM
CONTROL PANEL

FUSE

TRANSFORMER

Motor-protection
circuit-breaker Q1
(Grab)

Timing relay
K01, K02, K03,
Motor-protection circuit- K04, K05
breaker Q2, Q3
(DRUM)
Motor-protection circuit-breaker:
Q1 = for the Motor of the Grab
Q2 = for the motor of the cable drum
Q3 = for the motor of the rope drum
Timing relay

K01 = 1.5 sec. – protection against direct reversing

K02 = 1.5 sec. – protection against direct reversing

K03 = 23 sec. – time of motor operation during closing

K04 = 11 sec. – time of operation of the motor during opening

K05 = 15 sec. – theoretical closing time


CABLE DRUM

Application:
The Cable drum have to tight the cable independent of the
position of the Grab during cargo operation.

Performance:
The pulling force of the Cable drum measured directly at
the cable is 900N ( 90 kg ) if the cable is completely
drummed on the body and
1200N ( 120 kg ) if the cable is completely drummed off the
body
Max Motor output on 440 V 60 Hz: 2,8 KW
Max current consumption of the Motor: 6,3 A
Operating and maintenance instructions for cable reeling drum
type KFM 8/600/11 Bo

The cable drum consists of the following components:


a) - electric motor
b) - turbo coupling
c) - spur gear
d) - drum body
e) - brake

b
Operation
During grab operation, the driving motor 27 is always running with rated speed, while the turbo coupling 17 is
entirely absorbing the slip which is necessary for cable drums. Turbo coupling and electric motor are designed
for 100 percent continuous running.

ATTENTION! Do not synchronize with hoisting and lowering the grab.

The driving shaft of the turbo coupling is constantly running at the motor's rated speed. The driven shaft of the
turbo coupling transmits the torque to the drum body via spur gear and this in the same rotation sense as the
cable is winding up. When the cable is unwinding, the driven shaft of the turbo coupling is running in the
rotation sense opposite to the driving motor and the driving shaft of the turbo coupling.
ROPE DRUM
Operating and maintenance instructions for rope reeling drum type KSM 2 Bo
The rope drum consists of the following components:

a) - electric motor
b) - turbo coupling
c) - spur gear
d) - drum body
e) - brake
a

d
b
c
Operation
During grab operation, the driving motor 07 is always running with rated speed, while the turbo coupling
05 is entirely absorbing the slip which is necessary for rope drums. Turbo coupling and electric motor
are designed for 100 percent continuous running.

ATTENTION! Do not synchronize with hoisting and lowering the grab.

The driving shaft of the turbo coupling is constantly running at the motor's rated speed. The driven shaft
of the turbo coupling transmits the torque to the drum body via spur gear and this in the same rotation
sense as the cable is winding up. When the cable is unwinding, the driven shaft of the turbo coupling is
running in the rotation sense opposite to the driving motor and the driving shaft of the turbo coupling.

a) Connecting the rope to be wound up


Introduce the untwisted rope through the interior of the drum body and fasten it by strain-relief clamp.
Before winding up the rope, adding 2 safety windings.

ATTENTION! Do not wind up rope when brake is not released.

b) Operation of brake
The solenoid-operated spring pressure brake prevents the rope from winding off when motor is turned
off. The brake is to be synchronized with the motor. When starting the motor, the springloaded disk is
lifted from the brake disk and the brake is released. When cutting off the circuit, the springloaded disk is
pressed towards the brake disk and the brake is put on.

ATTENTION! The braking is to be adjusted in a way that no rope can wind off by itself, if the equipment
is out of operation. On the other hand, the adjustment shall allow the drum body to be turned manually,
if the motor is turned off.
TURBO COUPLING
Turbo coupling 274

SHAFT SEALS

filler screw
fuse screw
SHEAVES

Deflection Sheave Guide Sheave Deflection Sheave


(Rope) (Cable) (Cable)
SWITCH

1. Combination switch
This switch is used for the semi-automatic grab control system,
but can also be used for manual control. There is a green
indicator lamp on the cover and a selector switch with the
following three positions (manual, zero and semi-automatic). The
switch lever automatically returns to the neutral position. Control
is possible only when switch lever is pushed down. When the
green indicator lamp lights up crane hoist motor can be started. 2
The steel sheet case has IP 55 protection.

2. Foot-operated switch
This switch can be installed parallel to the combination
switch for semi-automatic control.
Protection: IP 54
3. Reversing switch
For separate reeling up and reeling off the electric
cable by the motor cable drum and/or the stabilizing
rope by the motor stabilizing drum. The plastic
housing has IP 54 protection. The switch has a
neutral position.
Cable lead-in above and below, 2 x Pg16.
CABLE SOCKET
GRAB

PUTTING INTO OPERATION


GREASING
SUSPENSION

UPPER
STEERING ARMS
CYLINDER
BEARINGS

LOWER SCOOP PIVOT


STEERING ARMS POINTS
CHECKING

PIN LOCKING

HOSES

PIN LOCKING

FILTER

OIL ELECTRICAL
LEVAL PIN LOCKING PIN LOCKING CONNECTION
CONNECTING STEEL
CABLE
WIRE
TESTING

FUNCTION

CYCLE
TIMES

CLOSING
OPENING PRESSURE
PRESSURE
ADJUSTING Dependent on cargos density
reduce number of kickplates

MZGL 12500
Deadweight:9.065 kg
Required crane lifting capacity: 24.000 kg

Filling volume Piled density adm. GRAB


[m³] [t/m³] lifting capacity
/ SWL [t]
V1 = 12,5 1,2 15,0
V2 = 10,0 1,5 15,0
V3 = 8,5 1,75 14,87
V4 = 7,0 2,1 14,7
V5 = 5,3 2,8 14,84

Product: MZGL 13000


Deadweight: 8.995 kg MZGL 14000
Deadweight: 9320 kg
Required crane lifting capacity: 23.945 kg Required vrane lifting capacity: 27.920 kg

Filling volume Piled density adm. lifting


Filling volume Piled density adm. GRAB
[m³] [t/m³] capacity / SWL
[m³] [t/m³] lifting capacity /
[t]
SWL [t]
V1 = 13,0 1,15 14,95
V1 = 14,0 1,3 18,2
V2 = 11,0 1,35 14,85
V2 = 12,0 1,55 18,6
V3 = 9,0 1,65 14,85
V3 = 10,0 1,85 18,5
V4 = 7,0 2,1 14,85
V4 = 8,5 2,15 18,3
V5 = 5,5 2,95 14,75
V5 = 6,5 2,8 18,2
Cargo; piled density (γ)
and angle of repose (α)

grain coal aggregates


γ = 0,6 – 0,8 α =30° γ = 0,8 – 1,0 α =40° γ = 1,3 – 1,6 α =30°

bauxite fertilizer iron ore


γ = 1,1 – 1,6 α =30° γ = 1,0 – 1,4 α =30° γ = 1,8 – 2,6 α =35°
PUTTING INTO OPERATION
CHECKING
SWITCHES MUST BE SWITCHES MUST BE
0FF (0 Position) 0FF (0 Position)

Motor-protection FUSE Setting of Timing relay


circuit-breaker (Green = O.K.) K01, K02, K03, K04, K05
Q1, Q2, Q3
TESTING
SWITCH ON SWITCH ON

RELEASE CABLE &


ROPE CAREFULY!
PREPARATION

CHECK!
CONNECTING STEEL
CABLE
WIRE
OPERATION SWITCHES MUST BE
ALWAYS ON
PULLING DIRECTION!

SWITCHES ON SWITCHES ON SEMI


MANUAL = AUTOMATIK =
ONLY MANUAL SWITCH & FOOD
OPERATION PEDAL OPERATION
(WITHOUT FOOD GRAB OPERATES
PEDAL) ATOMATICALY
GRAB

STEPS DURING
OPERATION
1. To close the grab perfectly,
lift up the grab slightly during closing

2. For a maximum filling rate


the grab should be set down
horizontally

3. Heavy impacts should be avoided,


In order to prevent dameges
DAILY
GREASING SUSPENSION

UPPER The bushes are made of LYTEX which is


made of composite material. This Material
STEERING ARMS has a good hard shaped surface, high load
bearing capacity and is ideal to be used in
salt water. A disadvantage is that dust is
working abrasive.
Grease in order to clean the bush.This will
extend the lifetime and reduces wear.

CYLINDER
BEARINGS

LOWER SCOOP PIVOT


STEERING ARMS POINTS
DAILY
CHECKING

PIN LOCKING

HOSES

PIN LOCKING

OIL ELECTRICAL
LEVAL PIN LOCKING PIN LOCKING CONNECTION
GRAB

STEPS TO PUT OUT OF


OPERATION
Clean the Grab completely with a
HIGH PRESSURE CLEANER

carry out a trial run without


bulk material !
check working condition of the
Hydraulik System and
fill out the test sheet for double check.
carry out necessary repairs
and order Spare Parts.
TESTING

FUNCTION

CYCLE
TIMES

CLOSING
OPENING PRESSURE
PRESSURE
CHECKING

PIN LOCKING

HOSES

PIN LOCKING

FILTER

OIL ELECTRICAL
LEVAL PIN LOCKING PIN LOCKING CONNECTION
GREASING
SUSPENSION

UPPER
STEERING ARMS
CYLINDER
BEARINGS

LOWER SCOOP PIVOT


STEERING ARMS POINTS
STORING

IN CLOSED
POSITION ONLY
(Piston Rods inside)

TURNBUCKELS
SUMMARY

the grab condition has to be


checked / carry out a test run

if necessary order
spare parts for next port

grab has to be placed


in closed and vertical position
Grab has to be cleaned
from cargo and cargo dust

grease must be applied to all


Lubrication points

the plastik hood ist to be


replaced
cover the plug in connector
by means of plastic cap
STEPS TO PUT OUT OF
OPERATION
CHECK!

SECURE
THE CABLE
AND WIRE
CHECKING
SWITCHES MUST BE SWITCHES MUST BE
0FF (0 Position) 0FF (0 Position)

Motor-protection FUSE Setting of Timing relay


circuit-breaker (Green = O.K.) K01, K02, K03, K04, K05
Q1, Q2, Q3 OFF
MAINTENANCE SCHEDULE
&
REPORT
GRAB

DAILY AFTER THE FIRST EVERY MONTH AFTER 1000


( DURING OPERATION ) 50 WORKING WORKING HOURS
HOURS
lubricate all bearings check and change lubricate all check grab working
check hoses, fittings the filter elements bearings conditions
and cylinder for tightness ( Use only Original check degree of oil
Filter elements cleanness carried out
supplied by SMAG) by the laboratory of the
oil supplier
change the oil
check and change the
filter elements

EVERY YEAR AFTER 4 YEARS

check grab working conditions CLASS SURVEY!!


check degree of oil cleanness change all hoses, fittings
carried out by the laboratory of open and clean the hydraulic system
the oil supplier clean the tank check grab working conditions
change the oil check degree of oil cleanness carried out by the laboratory
check and change the filter of the oil supplier
elements change the oil
check and change the filter elements
GRAB
NO. ITEM INTERVAL

DURATION OF GRABS USE

WORKING HOURS

TOTAL WORKING HOURS

1 LUBRICATION OF ALL BEARINGS DAILY

2 INSPECTION OF HOSES, FITTINGS DURING CARGO

3 INSPECTION OF SUSPENSION OPERATION

4 INSPECTION OF CABLE AND PLUG

5 INSPECTION OF PISTON ROD AND SEALING

6 REPAIRS DURING OPERATION

7 CLEANING GRAB AND ITS INNER HOOD AREA AFTER COMPLETION

8 LUBRICATION OF ALL BEARINGS OF EACH CARGO

9 INSPECTION OF HOSES, FITTINGS OPERATION

10 INSPECTION OF SUSPENSION

11 INSPECTION OF CABLE AND PLUG

12 INSPECTION OF PISTON ROD AND SEALING

13 CHECK OF OIL LEVEL

14 INSPECTION OF FILTER ELEMENTS

CHECK GRABS WORKING CONDITION


15 OPENING / CLOSING PRESSURE

CHECK GRAB ACCESSORIES


16 CABLE, ROPE, DRUMS AND SHEAVES

17 REPAIR REQUIRED & PART

REPAIR SUCCESSFUL DONE


18 Y/N

19 ISSUE & SIGN GRABS MONITORING REPORT

23 FILTER CHANGE / DATE EVERY YEAR

24 OIL CHANGE / DATE

TANK AND SYSTEM CLEANING


25 HOSES CHANGE AFTER 4 YEARS

RESPONSIBLE FOR INSPECTION


ACCESSORIES

Solenoid-operated spring pressure brake


The brake should be checked for its proper function in regular intervals. When the
brake lining should be changed please make certain, that they are absolutely grease
and oil free. There should be no grooves in the brake area.

Three-phase current motor


Only after about 5000 working hours the motor bearings will have to be refilled with
suitable high temperature grease (drop point at between 170° and 190° celsius
approximately). Before closing the terminal box cover shall be slightly spread with
grease. Please observe the instruction plate inside the cover.

Turbo coupling
The hydraulic oil of the turbo coupling is to be lubricated after 5000 working hours. In
the factory the turbo coupling has been filled with hydraulic oil.
Shell Tellus C 22 ISO-VG-22 22 cSt / 40 °C; 4,3 cSt / 100 °C.
Only fill in hydraulic oil with the same viscosity.
Please observe the enclosed technical description of the turbo coupling.
ACCESSORIES

Spur gear
The oil of the spur gear is be renewed, according to the working hours, every 12 - 18
months. It is recommended to drain the oil by taking off the lower locking screw
immediately after having stopped the drum. If possible, refill the gear with same type of
oil.

Sort of oil: synthetic oil brand - Mobil Glygoyle 30


When changing the oil, beware of dust particles which might penetrate into the gear.
OIL & GREASE
RECOMMENDATION
Table: Oil recommendation - Hydraulic fluids

For normal operation, a hydraulic fluid of ISO-viscosity VG 46 shall be used. For summer or
winter operation, a hydraulic fluid of ISO-viscosity VG 68 or FB 32 is to be used according
to the ambient temperature.

Degree of oil cleanness:

According to the ISO- code 4406, to the maximum contamination level of the oil.
(Laser - particulate-emission measurement ISO- code 11171, ISO MTD)

The particulate-emission limit for the grabs oil is:

ISO 17 – 16 – 13

Specific Water Content:

Max 300 PPM or 0.3 %


GRAB

Table: OIL recommendation


Winter Summer

ISO viscosity VG 32 VG 46 VG 68

Standard HVLP 32 HLP 46 HLP 68


acc. to DIN 51524/3 HV acc. to DIN51524/2 acc. to DIN51524/2

Range of oil temperature -20°C to +80°C -5°C to +80°C 0°C to +80°C

Ambient temperature < -5°C to -20°C -5°C to +30°C > +30°C

ARAL Vitam HF 32 Vitam GF 46 Vitam GF 68

BP ENERGOL SHF 32 ENERGOL HLP 46 ENERGOL HLP 68

CASTROL HYSPIN AWH 32 HYSPIN AWS 46 HYSPIN AWS 68

ESSO UNIVIS J 32 NUTO H 46 NUTO H 68

MOBIL DTE 13 DTE 25 DTE 26

SHELL Tellus Oel T 32 Tellus Oel 46 Tellus Oel 68

TEXACO Rando Oil HD AZ-32 Rando Oil HD B-46 Rando Oil HD C-68
GRAB

Table: Grease recommendation

Adhesive grease Lithium saponified grease lubricant


DIN 51825/2 KTA-L2k
DIN 51513 BC
AGIP FIN 332/F Longlime Grease 2

ARAL Sinit FZL 3 Aralub HL 2

AVIA Avilub BB 21 Avilub special grease WL

BP Energol WRL Energrease LS 2

Calypsol Eculit ST Calypsol H 442

Castrol Grippa 60 S Spheerol AP 2 LZV-EP


Spheerol E PL 2
DEA Trixolit 2X Glissando 20

DEFROL Defrol BC Defrol Fett KTA-L2k

ESSO Surett Fluid 4K Beacon 2

FINA Cabline 1060 Marson LU

Fuchs Duotac F 310 L Renolit MP

Mobil Oil Mobiltac D Mobilux 2

Shell Cardium Fluid C Alvania R 2


Alvania G 2
GRAB ACCESSORIES

Filling by manufacturer

Cable drum 4.5 l oil Mobil Glygoyle 30


Rope drum 1.8 l oil Aral Degol GS 220
Turbo coupling 2.0 l oil Shell Morlina 22 anciently Tellus C22

Gear unit

Brand synthetic oil ISO VG 220 for ambient temperatures of - 30°C to + 130°C.

Aral Degol GS 220


BP Energol SG XP 220
Esso Circulation oil 220
Mobil Glygoyle 30
Shell Tivela oil WB
Texaco Rando oil HD CZ 68 X

Other brands with the same quality level can be also used.

Turbo coupling

The quality of the oil is of particular importance. Therefore, for oil change we advise to employ the
above mentioned oil exclusively.
GUIDE FOR TROUBLE
SHOOTING
01. Guide to Examination
The Basic requirement of this instruction is that the problem was known by the SMAG Service
Department in the past. So please help us to update these instructions continuously. Please
contact and inform the SMAG Peiner Grab service department if you getting knowledge abou
problems which are not mentioned in this instruction.

Thank you very much in advance for your kind cooperation.

This instruction will show how to find the reason for a problem
And how to solve this problem.

Important:
Please check the grab condition intensive and carry out small repairs previously.

For further instructions fill it out


and send it to SMAG PEINER GRABS SERVICE DEPARTMENT
Problem:
Oil leakage at guide nut
of lifting cylinder. Damaged or worn our
Sealings
Problem: Oil leakage at guide nut of lifting Cause Action
cylinder
Sealing rings worn out due to normal wear during •Disassemble piston rod and guide nut. Check piston rod
operation. and cylinder tube for damages and scratches. Change
piston and guide sealing rings.

1/B. Disassemble guide nut and change sealing of guide


nut.

Info under: PART 02 MZG_CHANGING SEALINGS OF


HYDRAULIK CYLINDERS -
MZG_HOW TO DISASSEMBLE THE PISTON ROD

Sealing rings damaged by damaged piston rod •Disassemble piston rod and guide nut. Change piston rod
and sealing from piston and guide nut. Check cylinder tube
for scratches.

1/B Disassemble piston rod and guide nut.


2/B Slip out damaged areas of piston rod and change
sealing rings of guide nut.

Info under: PART 02


MZG_CHANGING SEALINGS OF HYDRAULIK
CYLINDERS -
MZG_HOW TO DISASSEMBLE THE PISTON ROD
Problem:
Grab opens and close
itself after Grab closed
or open and motor stopped

a) Internal leakage in lifting


cylinder
(Piston Seal)

b) Internal leakage in the control


block (SV1 / R1)
Problem: Grab opens or close itself Cause Action
Sealing rings of lifting cylinder are worn out due to normal 1. Disassemble lifting cylinder
wear during operation. 2. Change sealing rings from piston and guide nut
3. Check cylinder tube for damages and scratches
4. Change the oil and filter
5. Clean the tank and hydraulic hoses

Sealing rings damaged by dirt in the hydraulic system. Info under:


PART 02
MZG_CHANGING SEALINGS OF HYDRAULIK
CYLINDERS -
MZG_HOW TO DISASSEMBLE THE PISTON ROD

None return valves SV and / or RV are worn out due to 1. Disassemble control block
normal wear during operation 2. Clean valves and drillings
OR
None return valves SV and / or RV are worn out due to 1. Disassemble control block
dirt in the hydraulic system 2. Change valves SV and / or RV
3. Clean all drillings and other valves
4. Change the oil and filter
5. Clean the tank and hydraulic hoses

PART 02
MZG_CHANGING SEALINGS OF HYDRAULIK
CYLINDERS -
MZG_HOW TO DISASSEMBLE THE PISTON ROD
MZG_S3_CONTROL BLOCK_NG30E
Problem:
Grab is not working with
enough force
b) Huge internal leakage in lifting
cylinder

c) None return valves damaged or


worn out

a) DV1 / DV2 are not working


correcty

d) Hose or hose-connections
inside the take are loosen or
broken

e) Check valves RV 3 or and RV 4


damaged
or worn out

f) Pump is damaged or worn out

g) Pump regulators are damaged


or worn out
Problem: Grab is not working with enough force. Cause Action

Huge Internal leakage in lifting cylinder due to damaged Check for internal leakage as mentioned under 140
sealing rings as mentioned previously.
Info under : PART 01
MZG_HOW TO CHECK INTERNAL LEAKAGE

Check valves RV 3 or / and RV 4 damaged and / or worn Disassemble pump and check valve seats.
out due to dirt in the hydraulic system or due to oldness of Change check valves.
the grab.

Info under: PART 03


MZG_S3_CONTROL BLOCK_NG30E

Hydraulic pump is damaged and / or worn out due to Check pump working parameters. Try to adjust the
oldness of the grab or due to dirt in the hydraulic system pressure to max and also to minimum to ensure that the
or it was damaged due to overheating the hydraulic DV valves are working correctly.
system. Change pump if necessary.

Info under: PART 01 /03


MZG_Test Sheet
MZG_HYDRAULIC PUMP
Problem: Grab is not working with enough force. Cause Action

Dv1 and / or DV2 are not working correctly due to dirt in Check if valves are working correctly. Try to adjust the
the valve housing or DV valves are worn out due to pressure.
oldness of Grab. Change valves if necessary.

Info under: PART 03


MZG_S3_CONTROL BLOCK_NG30E

Hose or hose connections inside the tank are loosen or Disassemble hydraulic unit.
broken due to vibrations during normal operation or Check hoses and connections.
oldness of hoses and / or over pressure. If necessary change hoses and connections.
Or Hydraulic system was overheated
Info under: PART 03 MZG_HYDRAULIC PUMP_2 -
MZG_HYDRAULIC PUMP_3

Pump regulators damaged and / or worn out due to dirt in Check pump working parameter especially the rated
the hydraulic system or they are worn out due to normal current if the pump is moving. Change pump if necessary.
wear or hydraulic system was overheated
Info under: PART 01
MZG_Test Sheet

None return valves SV blocked due to dirt in the valve Disassemble valves
housing Check valve seats
Clean valves if necessary change valves.

Info under: PART 03


MZG_S3_CONTROL BLOCK_NG30E
Problem:
Grab is not closing completely
with cargo
a) Operator is not lifting the grab
up

b) Working pressure is too low

1.
d) Steering arm bushes are worn
out

c) Scoop bushes are worn out

e) Grain size of the cargo is too big

f) Scoop lips are worn out


Problem: Grab is not closing completely with Cause Action
cargo.

Bushes worn out due to normal wear and tear during Check if scoops and / or steering arms are moving in
operation their connection. (gab between pin and bush)
Disassemble Grab
Change bushes

Info under: PART 02


MZG_HOW TO DISASSEMBLE THE SCOOPS

Scoop lips worn out due to normal wear and tear Close the grab without cargo
during operation. Check the gab between the lips
Renew scoop lips by hard surfacing
Or by cutting worn out part and welding new parts at
the lips.
Or
Assemble side and bottom sealing lips.

Info under: PART 02


MZG_HOW TO DISASSEMBLE THE SCOOPS
MZG_ REPAIR OF LIPS

Pilled density of cargo is too big Review operation conditions of the grab

Info under: PART 01 MZG_PRESENTATION

Working pressure is too low Check grabs working pressure


Adjust the pressure
HOW TO ADJUST THE
PRESSURE
GENERAL:

The Peiner Grab Type MOTOR DUAL SCOOP GRAB ( MZG )


is equipped with 7 measuring points.
Which are as follows:

MP2

Cylinder

MP1

MLS MA MB
CLOSING PRESSURE:

LOAD SENSING (LS) PRESSURE

•MP1 – PUMP working Pressure


•Pressure produced by the pump, limited by the pressure
•release valve DV1 for"closing".
•The pressure finally has to be checked and adjusted by
•measuring at this point.
•The pressure can only be checked if the pump is running.

MA - SYSTEM pressure –
OPENING (QUICK RUN MOTION)
& CLOSING
Pressure in the hydraulic lines.
Due to physical rules, the pressure measured here is
approx. 30 to 40 bar higher than the pressure actually
produced by the pump.
Pressure can be checked if the Motor is stopped.

MLS – Pressure for the PUMP


regulator
Pressure in the load-sensing signal line to the load-
sensing regulator of the pump. The pressure measured
here is approx. 20 to 30 bar higher than the pressure
actually produced by the pump.
•The pressure can only be checked if the pump is
running
OPENING PRESSURE
OPENING PRESSURE
with QUICK RUN MOTION
LOAD SENSING (LS) PRESSURE

•MP2 – PUMP working Pressure


•Pressure produced by the pump, limited by the pressure
•release valve DV2 for“opening".
•The pressure finally has to be checked and adjusted by
•measuring at this point.
•The pressure can only be checked if the pump is running.

MB - SYSTEM pressure – OPENING


Pressure in the hydraulic lines.
Due to physical rules, the pressure measured here is
approx. 30 to 40 bar higher than the pressure actually
produced by the pump.
Pressure can be checked if the Motor is stopped.

MLS – Pressure for the PUMP


regulator
Pressure in the load-sensing signal line to the load-
sensing regulator of the pump. The pressure measured
here is approx. 20 to 30 bar higher than the pressure
actually produced by the pump.
•The pressure can only be checked if the pump is
running
PRESSURE PROFILE - MZG

280 Pressure MP1


260 Pressure MLS
240
220 Pressure MP2
200 Pressure MA
180
PRESSURE (bar)

160
140
120
100
80
60
40
20
0
1 6 11 16 21 26 31 36 41
TIME

CLOSING MOTOR OPENING MOTOR CLOSING


STOP STOP
300
250
Pressure MP1
200
Pressure MLS
150
Pressure MP2
100
Pressure MA
50
0
1

13

17

21

25

29

33

37

41

45

49

53

57

61

65

69

73

77

81

85

89

93

97

101

105

109

113

117

121
NOTE!
The Working Pressure has to be checked and adjusted at operating
temperature of the Hydraulic system with has to be approx between
30 and 60 °C.
Due to technical reasons the measured pressure as well as the rated
current of the grab motor at a “cold” system is higher then the declared
and factory-adjusted pressure.

Carry out a test run with the Grab to heat up the system to the operation
temperature before you make any new pressure settings.

All working pressure settings are done by measuring the


pressure at the measuring point:

MP1 for closing pressure


MP2 for opening pressure
The adjusted working pressure is declared at the type label which is assembled at the
upper traverse.And in the MACHINERY DATA CARD which you can find in the
DOKUMENTATION of our Grab.

CLOSING Pressure
Checked and adjusted via
messuring point MP1

OPENING Pressure
Checked and adjusted via
messuring point MP2
LEFT
DE SI
Pressure adjustment is done at the control block:

Closing pressure: Pressure release valve DV1


Opening pressure: Pressure release valve DV2
DV2

DV1
MOTOR SIDE

FRONT

URE
CLOSING PRESS

RE
OPENING PRESSU
•The adjustment itself is to be done as follows:

1. Connect a pressure gauge to measuring point MP1 resp. MP2.

2. Check the existing pressure (operation into closing resp. opening direction).

3. Lower pressure = Loosen the counter nut at DV1 resp. DV2 and turn the
adjustment screw to the left (anti-clockwise).

4. Then check the pressure and secure the adjustment screw.

5. Raise pressure = Loosen the counter nut at DV1 resp. DV2 and turn the
adjustment screw to the right (clockwise).

6. Then check the pressure and secure the adjustment screw.

NOTE!
NEW Control Blocks are not Factory adjusted.
Before you put them into operation you have to loosen
the counter nut at DV1 resp. DV2 and turn the
adjustment screw to the left (anti-clockwise) 4 times
around.
HOW TO CHECK INTERNAL
LEAKAGE
Repair operations planning and scheduling:

Following tools, equipment and staff have to be


available:

1 Crane for grab operation


1 Crane operator
1 Crane operating instructor
2 skilled workers

1 set of SMAG Peiner Grab tools


No.:23009997
Problem:
Grab opens and close
itself after Grab closed
or open and motor stopped

a) Internal leakage in lifting


cylinder
(Piston Seal)

b) Internal leakage in the control


block (SV1 / R1)
GRAB CLOSED &

PRESSURE
SV1
STAYS IN THE CLOSED
CONDITION

CYLINDER!
R1
CLOSED
CONDITION
Repair description:
Note: This test can only be carried out in closed
grab position due to the
QUICK RUN ACTION of the grab both lines A and
B are under pressure if grab is open.

Repair sequence:
1. hang the grab in the crane

2. connect the cable

3. close the grab slightly

4. connect the manometer at


measuring point MA
5. disconnect the Hydraulic hoses
which are assembled at the cylinder bottom

6. collect oil which is temporally coming


out of the connection

5.
8.

7. by using the grabs hydraulic


close the grab.

8. check if oil is leaking out


of the bolted joint of the cylinder

9. if not check if pressure rise down at the manometer


⇒ internal leakage must be inside the control block.

10. if oil is coming out of the cylinder


⇒ sealing rings or tube must be damaged or worn out.
If oil is coming out of the cylinder
⇒sealing rings or tube must be damaged or worn out.
⇒Have a look at instruction no.:
PART 02
HOW TO DISASSEMBLE THE PISTON ROD
PART 03
CHANGING SEALINGS OF HYDRAULIK CYLINDERS

If the cylinder is o.k and pressure rise down at the manometer


⇒ internal leakage must be inside the control block.

Have a look at instruction no.:


PART 03
CONTROL BLOCK_NG30